Waterproofing system for exposed rock surfaces

ABSTRACT

Polymer Rubber Gel is heated to an elevated temperature and sprayed against the exposed rock to form a generally uniform surface. The Polymer Rubber Gel can be sprayed on the rock surface using a heated want coupled to a heated kettle. Then, a layer of I polyethylene is formed against the polymer rubber gel layer. Finally, a finish layer such as concrete, tile, brick or segmental wall block is placed against the outer side of the polyethylene layer.

PRIORITY

This application claims the priority benefit of U.S. ProvisionalApplication No. 62/060,667 filed on Oct. 7, 2014, which is herebyincorporated herein by reference in its entirety.

FIELD

The present invention relates generally to systems and methods forwaterproofing structures having exposed rock surfaces.

BACKGROUND

Exposed rock walls are formed when roads and tunnels are carved out ofor into rock formations. In such situations, it is often necessary tocover the rock wall. Typically this is done by spreading concrete overthe rock wall to make it smooth and then covering the concrete layerwith a lining material. However, such methods are slow, labor intensiveand expensive to install. Moreover, there is a risk that the concretelayer will not adequately adhere to the exposed rock, or that theconcrete layer will separate from the rock in the future. Additionally,the concrete layer is not an effective waterproofing layer.

Thus, there is a need to provide a system that addresses some or all ofthe deficiencies discussed above.

SUMMARY

The present invention provides a unique finishing and waterproofingsystem for exposed rock surfaces. Polymer Rubber Gel is heated to anelevated temperature and sprayed against the exposed rock to form agenerally uniform surface. The Polymer Rubber Gel can be sprayed on therock surface using a heated want coupled to a heated kettle. Then, alayer of I polyethylene is formed against the polymer rubber gel layer.Finally, a finish layer such as concrete, tile, brick or segmental wallblock is placed against the outer side of the polyethylene layer.

The disclosure includes a method of providing a waterproofing and vaporbarrier to an exposed rock surface. The method includes heating anon-curing polymer rubber gel to a temperature to allow the non-curingpolymer rubber gel to be sprayed with a spray wand applicator. Thepolymer rubber gel is sprayed onto the exposed rock surface until acontinuous layer of the polymer rubber gel material is formed over theexposed rock surface. A layer of polyethylene sheet is disposed againstthe layer of polymer rubber gel. The polyethylene sheet has a first sideand an opposing second side. The first side of the sheet is in contactwith the continuous layer of the polymer rubber gel. A concrete layer isformed adjacent the polyethylene sheet such that the concrete layercontacts the second side of the polyethylene sheet.

The disclosure also includes a method of providing a waterproofingbarrier to an exposed natural rock surface. The method includes heatinga non-curing polymer rubber gel comprising 99% solids to a temperaturesufficient to allow the non-curing polymer rubber gel to be sprayed ontothe exposed natural rock surface with a spray wand applicator. Thepolymer rubber gel is sprayed onto the exposed natural rock surfaceuntil a continuous layer of the polymer rubber gel material is formedover the exposed natural rock surface. A layer of polyethylene sheet isdisposed against the layer of polymer rubber gel. The polyethylene sheethas a first side and an opposing second side. The first side of thesheet is in contact with the continuous layer of the polymer rubber gel.A finish layer is formed adjacent the polyethylene sheet such that thefinish layer contacts the second side of the polyethylene sheet.

The disclosure further includes a method of waterproofing a tunnelformed through rock to define an exposed rock surface. The methodincludes heating a non-curing polymer rubber gel to a temperaturesufficient to allow the non-curing polymer rubber gel to be sprayed ontothe exposed rock surface of the tunnel with a spray wand applicator. Thepolymer rubber gel is sprayed onto the exposed rock surface of thetunnel until a continuous layer of the polymer rubber gel material isformed over the exposed rock surface of the tunnel. A continuous layerof polyethylene is formed over the layer of polymer rubber gel. Thepolyethylene layer has a first side and an opposing second side. Thefirst side of the polyethylene layer is in contact with the continuouslayer of the polymer rubber gel. A finish layer is formed adjacent thepolyethylene layer such that the finish layer contacts the second sideof the polyethylene layer.

The above summary is not intended to limit the scope of the invention,or describe each embodiment, aspect, implementation, feature oradvantage of the invention. The detailed technology and preferredembodiments for the subject invention are described in the followingparagraphs accompanying the appended drawings for people skilled in thisfield to well appreciate the features of the claimed invention. It isunderstood that the features mentioned hereinbefore and those to becommented on hereinafter may be used not only in the specifiedcombinations, but also in other combinations or in isolation, withoutdeparting from the scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic side cross-sectional view of a waterproofingsystem for exposed rock surfaces according to certain exampleembodiments.

FIG. 2 is a schematic perspective view of an exposed rock surfacewaterproofing system applied to the inside of a tunnel according tocertain example embodiments.

FIG. 3 illustrates spray application of Polymer Rubber Gel using anapplication wand according to certain example embodiments.

While the invention is amenable to various modifications and alternativeforms, specifics thereof have been shown by way of example in thedrawings and will be described in detail. It should be understood,however, that the intention is not to limit the invention to theparticular example embodiments described. On the contrary, the inventionis to cover all modifications, equivalents, and alternatives fallingwithin the scope of the invention as defined by the appended claims.

DETAILED DESCRIPTION

In the following descriptions, the present invention will be explainedwith reference to various exemplary embodiments. Nevertheless, theseembodiments are not intended to limit the present invention to anyspecific example, environment, application, or particular implementationdescribed herein. Therefore, descriptions of these example embodimentsare only provided for purpose of illustration rather than to limit thepresent invention.

Referring to FIG. 1, the wall system 100 is shown according to oneexample embodiment. The rock surface 102 is covered with a layer ofPolymer Rubber Gel 104, preferably by spraying, to a thickness or depthsuch that the layer is at least about 90-100 mils thick at its thinnestpoint, while presenting generally continuous smooth surface forreceiving a sheet layer of material.

Next, the sheet layer of material 106 is applied to the exposed polymerrubber gel layer 104. The sheet material 106 is Geo Textile FleeceHigh-density polyethylene (HDPE) or Linear low-density polyethylene(LLDPE). The sheet material 106 is laid directly against the polymerrubber gel layer 104 with the fleece side facing outward away from thegel layer 104. The sheet material 106 provides a vapor barrier.

The HDPE or LLDPE material is commercially available in 12×30 footrolls. The sheets are overlapped 6-12 inches on the seam. Bitumen tapeor heat welding is used to bond the separate sheets so that they areconnected to form a single continuous sheet.

In certain example embodiments, the sheet material 106 is approximately20 mils thick and may or may not include a textile backing. However,other thicknesses and compositions of the sheet material can be used incertain embodiments without departing from the scope of the invention.

The gel 102 and sheet material 106 layers form a water and vapor barriersandwich. Finally, a concrete slab 108 layer can be poured directlyatop/against the sandwich. Rebar can be placed within the concrete slab,if desired. Alternative finish coverings other than concrete slab can beused without departing from the scope of the invention, includingsegmental concrete wall blocks, bricks, tiles, etc.

The Polymer Rubber Gel material is a non-curing rubber emulsion withadhesive and cohesive physical characteristics. Such material iscommercially available from a variety of sources. The Polymer Rubber Gelmaterial is applied monolithically to create an impervious waterproofingmembrane. The Polymer Rubber Gel actively responds to movement of theHDPE/LLDPE substrate, while maintaining its exceptionally strongadhesive bond to both the exposed rock and sheet material surfaces.

Polymer Rubber Gel also exhibits the ability to self heal under directhydrostatic pressure due to its non-curing nature. Polymer Rubber Gelnever completely cures and remains as a flexible gel. Since it nevercures, it self-heals under hydrostatic pressure. Thus, if thewaterproofing and providing vapor barrier system 100 were accidentallypunctured or cut, or if the rock surface shifts or splits, during orafter installation, the Polymer Rubber Gel membrane will automaticallyheal itself and maintain its water-tight and vapor-proof integrity.

Due to Polymer Rubber Gel's responsiveness to substrate movement andvibration, there is no need for repair of cracks/separation in thewaterproofing membrane. In contrast, concrete, and other conventionalwaterproofing applications cure and crack, leading to water intrusion.Polymer Rubber Gel never completely cures, so it self-heals and canweather the constant stress of thermal expansion/contraction, seismicactivity and vibration that might be experienced in a wide variety ifapplications.

The Polymer Rubber Gel layer 104 also provides for creation of aseamless or continuous layer. Thus, there are no seams or gaps betweensections of the sandwich. There is formed a continuous membranethroughout the entire extent of the rock surface, and beyond. Thus,there are no seams or gaps where water and vapors can easily escape fromthe rock.

Not all Polymer Rubber Gels are the same. For example, different gelshave widely differing amounts of solids in their content. Thus, any twogiven gels will have very different material properties. Clearly, thehigher the solids content, the more viscous the gel material.

Polymer rubber gel is typically not flowable at room temperature. In oneaspect of certain embodiments of the invention, the polymer rubber gelis sprayed onto the exposed rock. To achieve flowability at roomtemperature to be able to spray the gel onto the exposed rock, a polymerrubber gel with high solids content such as 99% solids is preferred. Thehigh solids content is preferred because relatively thin polymer rubbergels, such as TURBOSEAL, which has approximately 78% solids, cannot bereliably heated and sprayed. The inventor has found that TURBOSEAL gelonly squirts from the wand when heated, rather than sprays. Furtherheating of the TURBOSEAL gel simply causes the material to break down.

By using a polymer rubber gel with a much higher solids content thanTURBOSEAL gel and the like, such as one with 99% solids, and heating thepolymer rubber gel to an elevated temperature of between 150-200° F.,the gel does not break down because it is almost entirely solids, but itis able to be successfully sprayed with a wand.

Referring to FIG. 2, the present system is shown being applied to atunnel formed through rock. The polymer rubber gel layer 104 is appliedto the inside exposed rock surfaces 102. Then the gel layer 104 iscovered with the vapor barrier sheet material 106 as discussed hereinabove. A finish layer of concrete, tile or other material can, but neednot be, applied to the sheet material's exposed surface.

By overlapping and detailing any joints and the corners of the HDPE/LDPEsheet with tape, or other seam closing means, the wall system becomescontinuous. This results in an encapsulating barrier surrounding theentire rock surface.

The wall system and method described herein offers numerous advantagesover other such systems. For example, the ease and effectiveness ofinstallation is superior. Thus the installer can be more productive andthe system is more cost effective doe to reduced labor costs, speed oftime to project completion and reduced mistakes in application. Thepresent invention also offers long-term effectiveness.

Additional advantages include, the sheet membrane does not requirechemical reaction, hydration, or compaction to bond to concrete. Thecombination of gel and sheet described herein creates an exceptionallydurable, dynamically responsive high performance waterproofing and vaporbarrier system that is effective in many adverse environments andconditions. Waterproofing integrity is maintained without loss ofadhesion to substrate or failure from membrane punctures as happens withconventional rock wall covering systems. Thus, a more effective wall andwaterproofing system is provided.

An additional aspect of the invention is a novel method of spraying theapplication of Polymer Rubber Gel (non-curing, self-healing rubbermastic spray material) to the exposed rock surface using modifiedasphalt crack sealing equipment (e.g., from Crafco).

In use, the procedure for the present system comprises:

-   -   1. Utilize oil jacketed kettle and pump system (e.g. crack seal        melter);    -   2. Load Polymer Rubber Gel (with 99% solids) into the hopper of        the kettle;    -   3. Turn on the kettle and run the kettle temperature to 260-270        degrees F.;    -   4. Wait until the Polymer Rubber Gel liquefies; and    -   5. Spray the Polymer Rubber Gel from a hydraulic pressure pump        to a thickness of 90-100 mils minimum.

FIG. 3 illustrates the spray application of Polymer Rubber Gel using theapplication wand of the modified asphalt crack sealing equipment. Notethat the wand and feed hose are both preferably heated as well, so thatthe temperature of the liquefied gel can be maintained.

While the invention has been described in connection with what ispresently considered to be the most practical and preferred embodiments,it will be apparent to those of ordinary skill in the art that theinvention is not to be limited to the disclosed embodiments. It will bereadily apparent to those of ordinary skill in the art that manymodifications and equivalent arrangements can be made thereof withoutdeparting from the spirit and scope of the present disclosure, suchscope to be accorded the broadest interpretation of the appended claimsso as to encompass all equivalent structures and products. Moreover,features or aspects of various example embodiments may be mixed andmatched (even if such combination is not explicitly described herein)without departing from the scope of the invention.

What is claimed is:
 1. A method of providing a waterproofing and vapor barrier to an exposed rock surface, the method comprising: heating a non-curing polymer rubber gel to a temperature to allow the non-curing polymer rubber gel to be sprayed with a spray wand applicator; spraying the polymer rubber gel onto the exposed rock surface until a continuous layer of the polymer rubber gel material is formed over the exposed rock surface; disposing a layer of polyethylene sheet against the layer of polymer rubber gel, the polyethylene sheet having a first side and an opposing second side, wherein the first side is in contact with the continuous layer of the polymer rubber gel; and forming a concrete layer adjacent the polyethylene sheet such that the concrete layer contacts the second side of the polyethylene sheet.
 2. The method of claim 1, wherein the second side of the polyethylene sheet comprises fleece material.
 3. The method of claim 1, wherein the polyethylene sheet comprises High-density polyethylene (HDPE).
 4. The method of claim 1, wherein the polyethylene sheet comprises Linear low-density polyethylene (LLDPE).
 5. The method of claim 1, further comprising: disposing as second polyethylene sheet against the layer of polymer rubber gel such that the second sheet partially overlaps the first sheet to define a seam; and sealing the seam of the overlapped first and second polyethylene sheets to form a continuous polyethylene layer.
 6. The method of claim 5, further comprising sealing the seam by applying bitumen tape to the seam.
 7. The method of claim 5, further comprising sealing the seam by heat welding the seam.
 8. The method of claim 1, wherein the polymer rubber gel comprises 99% solids.
 9. The method of claim 1, further comprising heating the polymer rubber gel to a temperature in the range of 150-200 degrees Fahrenheit before spraying the polymer rubber gel onto the exposed rock surface.
 10. The method of claim 1, further comprising: loading the polymer rubber gel into an oil jacketed kettle, the kettle including a pump coupled to the spray wand applicator, wherein the spray want applicator is heated to at least the same temperature as the polymer rubber gel; elevating the temperature of the polymer rubber gel inside of the kettle to liquefy the polymer rubber gel; and delivering the liquefied polymer rubber gel to the heated spray wand applicator under pressure.
 11. A method of providing a waterproofing barrier to an exposed natural rock surface, the method comprising: heating a non-curing polymer rubber gel comprising 99% solids to a temperature sufficient to allow the non-curing polymer rubber gel to be sprayed onto the exposed natural rock surface with a spray wand applicator; spraying the polymer rubber gel onto the exposed natural rock surface until a continuous layer of the polymer rubber gel material is formed over the exposed natural rock surface; disposing a layer of polyethylene sheet against the layer of polymer rubber gel, the polyethylene sheet having a first side and an opposing second side, wherein the first side is in contact with the continuous layer of the polymer rubber gel; and forming a finish layer adjacent the polyethylene sheet such that the finish layer contacts the second side of the polyethylene sheet.
 12. The method of claim 11, wherein the finish layer comprises a layer of concrete.
 13. The method of claim 11, wherein the finish layer comprises tiles.
 14. The method of claim 11, wherein the finish layer comprises bricks.
 15. The method of claim 11, wherein the second side of the polyethylene sheet comprises fleece material.
 16. The method of claim 11, further comprising: disposing as second polyethylene sheet against the layer of polymer rubber gel such that the second sheet partially overlaps the first sheet to define a seam; and sealing the seam of the overlapped first and second polyethylene sheets to form a continuous polyethylene layer.
 17. The method of claim 11, further comprising heating the polymer rubber gel to a temperature above 150 degrees Fahrenheit before spraying the polymer rubber gel onto the exposed natural rock surface.
 18. The method of claim 11, further comprising: loading the polymer rubber gel into an oil jacketed kettle, the kettle including a pump coupled to the spray wand applicator, wherein the spray want applicator is heated to at least the same temperature as the polymer rubber gel; elevating the temperature of the polymer rubber gel inside of the kettle to liquefy the polymer rubber gel; and delivering the liquefied polymer rubber gel to the heated spray wand applicator under pressure.
 19. A method of waterproofing a tunnel formed through rock to define an exposed rock surface, the method comprising: heating a non-curing polymer rubber gel to a temperature sufficient to allow the non-curing polymer rubber gel to be sprayed onto the exposed rock surface of the tunnel with a spray wand applicator; spraying the polymer rubber gel onto the exposed rock surface of the tunnel until a continuous layer of the polymer rubber gel material is formed over the exposed rock surface of the tunnel; forming a continuous layer of polyethylene over the layer of polymer rubber gel, the polyethylene layer having a first side and an opposing second side, wherein the first side is in contact with the continuous layer of the polymer rubber gel; and forming a finish layer adjacent the polyethylene layer such that the finish layer contacts the second side of the polyethylene layer.
 20. The method of claim 19, wherein the finish layer consists of one or more of the following materials: concrete, tile, brick and segmental wall block. 